Frequently Asked Questions About Automated Guided Vehicles

Moving items around the warehouse with safety, precision, and efficiency is important for facilities. With automation becoming more accessible, many operations have turned to Automated Guided Vehicles, or AGVs, to streamline material handling tasks.

AGVs are waypoint-guided vehicles that transport materials about a facility using automated navigation technologies. These material handling solutions take over repetitive tasks that forklifts or manually-operated carts might otherwise be doing. With a predetermined path made from sensors, magnetic tape, or markers such as QR codes, these automation solutions move with predefined predictable precision.

If you’re wondering how to create more efficiency within your facility, these frequently asked questions, explained by our St. Louis automation experts show how AGVs work and why they’re worth it.

General Questions About AGVs

What is an Automated Guided Vehicle?

An automated guided vehicle is a driverless vehicle that automates movement of material throughout your warehouse. These automation solutions follow a pre-determined route and can operate autonomously to reduce the manual transportation of items.

By automating these repetitive tasks, AGVs improve efficiency and save time for facilities by providing predictable and accurate workflows.

How do AGVs work?

AGVs work by following pre-determined routes using onboard and fleet-managed navigation technology, sensors, and software to move materials throughout a facility. Once an AGV is programmed, it will follow specific routes after receiving tasks and signals from a warehouse management system.

Once a task is generated, the AGV receives the task and then navigates to a pickup location. When the AGV is notified the item is present, it picks the item and transports the material to a drop-off destination, and the system will mark this task as complete.

What are the main components of an AGV system?

The main components of an AGV include:

• -The transportation unit, which is the AGV itself.
• -The navigation system, which maps out the route for the AGV. These can include tape, QR codes, reflectors, lasers, and more.
• -Sensors and safety devices: used to help the AGV monitor its surroundings and any obstacles in the way.
• -Control software: communicates with the WMS.
• -Power system: most AGVs are battery powered and use charging systems.
• -Method of moving material, i.e. either a hopper, forks, a cart, or a tow hitch for towed carts

What tasks can AGVs automate?

Tasks that AGVs can automate include pallet transport, movement of raw materials, work in process inventory, warehouse picking, warehouse replenishment, scrap material from machining operations, and more. By automating material movement, these driverless vehicles can work alongside workers to improve ergonomics, accuracy and keep production running smoothly.

Benefits & Performance Questions About Automated Guided Vehicles

What are the benefits of AGVs?

AGVs offer many benefits to warehouse systems including increasing safety and efficiency. By removing repetitive material handling tasks, AGVs bring many benefits to facilities looking to improve their operations.

Some of the benefits that AGVs have include:

• -Improved workplace safety: these material handling systems don’t tire out like workers might after taking many trips throughout a warehouse with heavy loads. They also include safety features that detect obstacles and people, which reduces injuries in the warehouse.
• -Efficient operations: having material movement automation reduces downtime and keeps things moving throughout the day. AGV’s even enable “lights-off” activity where the vehicles can accomplish replenishment or staging tasks overnight without human interaction, jump-starting your morning shift’s productivity
• -Scalability: these material handling systems can be used in different areas of your operations to expand in a more affordable way.
• -Improved accuracy: without human error, downtime is reduced from mistakes.

To find out how these driverless vehicles would specifically benefit your facility, reach out to our St. Louis automation experts here.

How do AGVs improve warehouse efficiency?

AGVs improve warehouse efficiency by establish predictable and reliable workflows, reducing travel time for workers and decreasing mistakes, which saves time and money. This ensures a continuous movement of materials throughout the day, and optimizes the workflow.

How do AGVs improve workplace safety?

AGVs improve workplace safety by creating safer routines for the movement of material. With features like sensors that can detect obstacles, these material handling solutions can work around employees, creating safer movement of heavy materials. These also take the manual work off workers, reducing the risk of fatigue for operators.

How do AGVs improve productivity?

Automated guided vehicles improve productivity by ensuring materials are accurately delivered to the right location at the right time. This reduces delays that may occur with manual labor as downtime is decreased, throughput is increased, and employees can then focus on other aspects at work.

Applications and Industries for AGVs

What industries use AGVs?

AGVs are used across a wide variety of industries that want to automate their movement of material to streamline workflows and reduce manual labor. Some of the industries that use AGVs include:

• -Warehousing and distribution
• -Manufacturing
• -Food and beverage
• -Retail
• -Pharmaceutical
• -Consumer goods
• -Automotive Manufacturing and Reman (Remanufacturing) operations

What are AGVs used for in warehouses?

In warehouses, AGVs are used to transport typically-palletized material throughout a facility, repeatedly and consistently throughout the day. Common warehouse applications include: pallet movement, inventory replenishment, order fulfillment support, keeping production lines stocked, and more.

Are AGVs used in manufacturing?

Yes, AGVs are used in manufacturing facilities to move items, work in process inventory, and finished goods between production areas.

As manufacturing operations typically require repetitive movement, these driverless vehicles are well suited to support the workflows in manufacturing facilities.

Are AGVs good for distribution centers?

Yes, AGVs are good for distribution centers and they help facilities process products quicker and more efficiently. AGVs can integrate into distribution centers by:

• -Transporting pallets of goods between storage and shipping areas
• -Improving order fulfillment workflows
• -Reducing congestion and injuries caused by manual equipment

Can AGVs transport pallets and heavy loads?

Yes, automated guided vehicles can transport pallets and heavy loads throughout a facility. AGVs can often replace forklifts as they can lift, transport, and stack palletized loads. These material handling solutions can also tow carts or trailers and transport containers around a facility.

AGV Navigation and Safety

How do AGVs navigate?

AGVs navigate by using a guidance system to sense their path that has been laid out. These navigation systems track the AGVs location and guide it to its destinations. Navigation methods can include:

• -Magnetic tape guidance
• -Laser navigation
• -Vision-based navigation
• -QR code or “spot” navigation
• -Magnetic spot or RFID navigation

Do AGVs use magnets, lasers, or vision systems?

Yes, automated guided vehicles can use magnets, lasers, or vision systems as their navigation technologies.

The magnetic navigation is one of the most common and cost-effective, allowing the AGV to follow a predetermined path.

Laser navigation uses laser scanners and reflectors to allow the AGV to measure its position relative to the reflectors.

Vision-based navigation includes the use of cameras and vision systems to identify landmarks throughout a facility. This type of navigation is beneficial for facilities where the environment may change more frequently.

Can AGVs avoid obstacles?

Yes, AGVs can avoid obstacles as they use sensors to identify objects in their path. These material handling systems will either stop or slowdown when something is detected to ensure a safe warehouse environment.

Are AGVs safe around employees?

Yes, AGVs can operate safely around employees as they have features like obstacle detection, warning lights, speed control systems, and more.

Can AGVs work alongside forklifts and people?

Yes, AGVs can work alongside forklifts and people as they can share space with both workers and manually operated equipment. With safety features in place, the proper planning and integration can ensure efficient and safe operations.

What safety features do AGVs have?

AGVs include a variety of safety features designed to protect warehouse workers and equipment in facilities. Some of these features include:

• -Obstacle detection sensors
• -Emergency stop systems
• -Warning lights and alarms
• -Speed control
• -Safety zones

Implementation Questions

How do you implement an AGV system?

Implementing an AGV system begins with a critical evaluation of your facility, existing and goal data, and understanding your operational workflow and goals. This is where our St. Louis material handling expert would do a facility assessment to understand transportation routes and material movement requirements.

Once the system is designed, the system is connected to software to automate task assignments and material movement. Then, the system can be installed, tested via System Acceptance Test and Facility Acceptance Test, and once employees receive training, the AGV can go live.

How long does it take to install AGVs?

The time it takes to install an AGV depends on the size of your project and the complexity included with the layout and type of tasks you need. Factors that can influence the time it takes to install one of these material handling solutions include facility size, number of AGVs being deployed, navigation method being used, and operational complexity.

Can AGVs be added to an existing warehouse?

Yes, AGVs can be added to an existing warehouse without needed a new facility. These material handling solutions offer flexibility for facilities wanting to improve their efficiency without rebuilding their entire operations.

Is it difficult to integrate AGVs into an operation?

Sometimes! AGVs can be easier to integrate into operations than most people may expect, however software and route preparation cannot be rushed and should be adequately evaluated prior to starting the project. These systems are able to integrate with WMS, ERP, and other facility systems to automate requests and task management, but these integrations must be planned carefully.

Operational Questions

Can AGVs integrate with a WMS?

Yes, AGVs can integrate with a WMS. This integration allows the WMS to send requests to the AGV, telling it to complete a task. This helps facilities automate transport requests, improve inventory visibility, increase workflow efficiency, and improve material flow throughout the warehouse.

Can AGVs connect to an ERP system?

Technically, AGVs could connect to an ERP system, however nearly every AGV manufacturer would strongly recommend or even require a WMS or at least a vendor-specific WMS-lite to coordinate operations at a lower more granular level than the ERP. ERP systems help businesses track inventory, purchasing, and order management but can fall short on specific location management and optimization, as well as picking and replenishing coordination. When integrated, the AGV can support production workflows, inventory movement, order fulfillment, and material replenishment activities.

How are AGVs controlled?

AGVs are controlled by a fleet management system and can act as a central command center that assigns tasks, manages routes, and monitors the vehicle locations. This can help to optimize travel routes and coordinate multiple vehicles.

Maintenance and Reliability Questions About AGVs

How long do AGVs last?

AGVs are designed for long term use. The lifespan of an AGV depends on how the solution is maintained over the years, the workload it sees day to day, facility conditions, and battery charging. Regular inspections, charging cycles, and maintenance can help extend the life of this material handling system.

What maintenance do AGVs require?

AGVs require routine inspections to ensure reliable operations. This can include: battery maintenance, sensor and safety system inspections, mechanical inspections, and software updates.

How are AGVs serviced?

AGVs are serviced through a combination of preventative maintenance, inspections, and software support. This can include inspections to ensure everything is working properly, and technical support to ensure the systems are running efficiently.

Learn More About Automated Guided Vehicles

Do you want to learn more about the benefits of an automated guided vehicle and how one could integrate into your operations? Chat with your St. Louis automotive expert at 833-754-2164 or fill out a form here, and someone will get back to you!